Intercooling for an axial compressor with radially outer annulus

ABSTRACT

An axial compressor comprises a plurality of compressor stages positioned axially adjacent one another within a casing. Each of the plurality of compressor stages comprise a rotor segment and a banded stator segment positioned axially adjacent the rotor segment. An annulus is formed between the casing and an outer flowpath ring of the stator segment. A vane of each stator segment comprises a member extending into the annulus.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 15/188,721 filed Jun. 21, 2016, the entirety ofwhich is hereby incorporated by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to fluid compression, and morespecifically to an axial compressor assembly.

BACKGROUND

Axial-flow compressors are used in a variety of applications to compressa fluid from an inlet pressure to a discharge pressure which is higherthan inlet pressure. Axial-flow compressors typically comprise arotatable assembly of a plurality of blades mounted to a rotor and astatic assembly of a plurality of vanes mounted to a casing. Thecross-sectional area of the fluid passage in an axial-flow compressortypically decreases as the fluid travels from inlet to discharge. Inoperation, the rotating blades accelerate the fluid into a diminishingcross-sectional area, thus compressing or pressurizing the fluid.

Applications of axial-flow compressors include, but are not limited to,gas turbine engines including those used in air-, land-, and sea-basedapplications for providing electrical generation and/or propulsion,expendable machines such as for missile propulsion systems, and otherrotating machinery generally. In many applications there is a need inthe art for axial compressors which can be achieved at a lower cost ofmanufacture and operation. Efforts to reduce the cost of manufacturehave included, for example, the substitution of metal engine componentswith those made of lightweight composite materials which tend to be lessexpensive to procure and machine to achieve the desired compressorcomponents. However, material substitution alone is insufficient toachieve the desired cost savings when manufacturing and operating anaxial compressor, particularly for expendable applications where themanufacturing cost is lost after a single use.

It is thus desired for an improvement in the art of manufacturing andoperating axial compressors to provide less expensive alternatives toexisting designs.

SUMMARY

The present application discloses one or more of the features recited inthe appended claims and/or the following features which, alone or in anycombination, may comprise patentable subject matter.

According to an aspect of the present disclosure, an axial compressorcomprises a plurality of compressor stages and a casing configured toencase the plurality of compressor stages positioned axially adjacentwithin the casing. Each of the plurality of compressor stages comprisesa rotor segment comprising a bladed disc configured to be coupled to arotatable shaft; a banded stator segment positioned axially adjacent therotor segment, the stator segment comprising an outer flowpath ring, aninner flowpath ring, and a plurality of vanes extending between therings and being spaced around the circumferences thereof, the statorsegment further comprising one or more tangs extending radially outwardfrom the outer flowpath ring to engage the casing and thereby space theouter flowpath ring radially inward from the casing forming an annulusbetween the casing and the outer flowpath ring; and a pathway providingan air flowpath between the annulus and the annulus formed by anadjacent stage.

In some embodiments a pathway in at least one of the stages comprises anaperture formed in the one or more tangs. In some embodiments the axialcompressor further comprises an entry pathway in a first of the stagesproviding an air flowpath between the main flowpath of the compressorstage and the annulus of the stage; and an exit pathway in a second ofthe stages positioned axially downstream of the first stage, the exitpathway providing an air flowpath between the annulus of the stage andthe exterior of the casing. In some embodiments the second stage is thefinal downstream stage of the compressor.

In some embodiments the first stage is one of the first or secondaxially upstream stages of the compressor. In some embodiments thestator segment most proximate the entry pathway comprises a plurality ofactuating stator vanes. In some embodiments the pathway is defined by atube extending between the entry pathway and the exit pathway. In someembodiments air flow through the pathway is induced by a differentialpressure between the air pressure proximate the entry pathway and theair pressure proximate the exit pathway, and wherein the differentialpressure is caused by operation of the axial compressor.

According to another aspect of the present disclosure, an axialcompressor comprises a plurality of compressor stages and a casingconfigured to encase the plurality of compressor stages positionedaxially adjacent within the casing. Each of the plurality of compressorstages comprise a rotor segment comprising a bladed disc configured tobe coupled to a rotatable shaft; a banded stator segment positionedaxially adjacent the rotor segment, the stator segment comprising anouter flowpath ring, an inner flowpath ring, and a plurality of vanesextending between the rings and being spaced around the circumferencesthereof, the stator segment further comprising one or more tangsextending radially outward from the outer flowpath ring to engage thecasing and thereby space the outer flowpath ring radially inward fromthe casing forming an annulus between the casing and the outer flowpathring; and a pathway providing an air flowpath between an entry apertureand an exit aperture, the entry aperture disposed in a first of thecompressor stages and providing an air flowpath between the bulkflowpath of the compressor stage and the annulus of the stage and theexit aperture disposed in a second of the stages positioned axiallydownstream of the first stage, the exit aperture providing an airflowpath between the annulus of the stage and the exterior of thecasing, wherein the entry aperture and the exit aperture are in fluidcommunication.

In some embodiments the annulus of one or more of the stator segments issubstantially filled with a filler. In some embodiments the filler atleast partially defines the pathway. In some embodiments the fillercomprises a metallic foam. In some embodiments the filler has a higherthermal conductivity in the radial direction than in the axialdirection. In some embodiments a plurality of pathways are defined bythe filler between the entry aperture and the exit aperture. In someembodiments the pathway in at least one of the stages comprises anaperture formed in the one or more tangs. In some embodiments the statorsegment most proximate the entry aperture comprises a plurality ofactuating stator vanes.

According to another aspect of the present disclosure, a method ofcooling an axial compressor comprises providing a plurality ofcompressor stages encased in a casing, the plurality of compressorstages positioned axially adjacent within the casing and each of theplurality of compressor stages comprise a rotor segment comprising abladed disc configured to be coupled to a rotatable shaft; a bandedstator segment positioned axially adjacent the rotor segment, the statorsegment comprising an outer flowpath ring, an inner flowpath ring, and aplurality of vanes extending between the rings and being spaced aroundthe circumferences thereof, the stator segment further comprising one ormore tangs extending radially outward from the outer flowpath ring toengage the casing and thereby space the outer flowpath ring radiallyinward from the casing forming an annulus between the casing and theouter flowpath ring; providing a pathway between an entry pathway and anexit pathway, the entry pathway disposed in a first of the compressorstages and providing an air flowpath between the bulk flowpath of thecompressor stage and the annulus of the stage and the exit pathwaydisposed in a second of the stages positioned axially downstream of thefirst stage, the exit pathway providing an air flowpath between theannulus of the stage and the exterior of the casing, wherein the entrypathway and the exit pathway are in fluid communication; and introducingair flow through the pathway.

In some embodiments the step of introducing air flow through the pathwaycomprises operating the compressor to establish a differential pressurebetween the air pressure proximate the entry pathway and the airpressure proximate the exit pathway. In some embodiments the methodfurther comprises the step of actuating a plurality of vanes of a statorsegment most proximate the entry pathway to alter the vane anglerelative to the direction of bulk flow. In some embodiments the annulusof one or more of the stator segments is substantially filled with afiller comprising a metallic foam, and wherein the filler at leastpartially defines the pathway.

According to yet another aspect of the present disclosure, an axialcompressor comprises a plurality of compressor stages and a casingconfigured to encase the plurality of compressor stages positionedaxially adjacent within the casing. Each of the plurality of compressorstages comprise a rotor segment comprising a bladed disc configured tobe coupled to a rotatable shaft; a banded stator segment positionedaxially adjacent the rotor segment, the stator segment comprising anouter flowpath ring, an inner flowpath ring, and a plurality of vanesextending between the rings and being spaced around the circumferencesthereof, the stator segment further comprising one or more tangsextending radially outward from the outer flowpath ring to engage thecasing and thereby space the outer flowpath ring radially inward fromthe casing forming an annulus between the casing and the outer flowpathring; and wherein each of the plurality of vanes comprises a memberextending into the annulus.

In some embodiments the axial compressor further comprises a pathwayproviding an air flowpath between the annulus and the annulus formed byan adjacent stage. In some embodiments a pathway in at least one of thestages comprises an aperture formed in the one or more tangs. In someembodiments the axial compressor further comprises an entry pathway in afirst of the stages providing an air flowpath between the main flowpathof the compressor stage and the annulus of the stage; and an exitpathway in a second of the stages positioned axially downstream of thefirst stage, the exit pathway providing an air flowpath between theannulus of the stage and the exterior of the casing.

In some embodiments the second stage is the final downstream stage ofthe compressor. In some embodiments the first stage is one of the firstor second axially upstream stages of the compressor. In some embodimentsthe stator segment most proximate the entry pathway comprises aplurality of actuating stator vanes. In some embodiments the pathway isdefined by a tube extending between the entry pathway and the exitpathway. In some embodiments air flow through the pathway is induced bya differential pressure between the air pressure proximate the entrypathway and the air pressure proximate the exit pathway, and wherein thedifferential pressure is caused by operation of the axial compressor. Insome embodiments each of the members passes through a respectiveaperture of the outer flowpath ring.

According to a further aspect of the present disclosure, an axialcompressor comprises a plurality of compressor stages and a casingconfigured to encase the plurality of compressor stages positionedaxially adjacent within the casing. Each of the plurality of compressorstages comprise a rotor segment comprising a bladed disc configured tobe coupled to a rotatable shaft; a banded stator segment positionedaxially adjacent the rotor segment, the stator segment comprising anouter flowpath ring, an inner flowpath ring, and a plurality of vanesextending between the rings and being spaced around the circumferencesthereof, the stator segment further comprising one or more tangsextending radially outward from the outer flowpath ring to engage thecasing and thereby space the outer flowpath ring radially inward fromthe casing forming an annulus between the casing and the outer flowpathring and wherein the annulus is substantially filled with a filler thatdefines one or more pathways between the annulus and the annulus formedby an adjacent stage; and wherein each of the plurality of vanescomprises a member extending into the annulus.

In some embodiments the annulus of one or more of the stator segments issubstantially filled with a filler. In some embodiments the fillercomprises a metallic foam. In some embodiments the filler has a higherthermal conductivity in the radial direction than in the axialdirection. In some embodiments the pathway comprises an air flowpathbetween an entry aperture and an exit aperture, the entry aperturedisposed in a first of the compressor stages and providing an airflowpath between the bulk flowpath of the compressor stage and theannulus of the stage and the exit aperture disposed in a second of thestages positioned axially downstream of the first stage, the exitaperture providing an air flowpath between the annulus of the stage andthe exterior of the casing, wherein the entry aperture and the exitaperture are in fluid communication.

In some embodiments a plurality of pathways are defined by the fillerbetween the entry aperture and the exit aperture. In some embodimentsthe pathway in at least one of the stages comprises an aperture formingin the one or more tangs.

According to another aspect of the present disclosure, a method isprovided of intercooling an axial compressor. The method comprisesproviding a plurality of compressor stages encased in a casing, theplurality of compressor stages positioned axially adjacent within thecasing and each of the plurality of compressor stages comprise a rotorsegment comprising a bladed disc configured to be coupled to a rotatableshaft; a banded stator segment positioned axially adjacent the rotorsegment, the stator segment comprising an outer flowpath ring, an innerflowpath ring, and a plurality of vanes extending between the rings andbeing spaced around the circumferences thereof, the stator segmentfurther comprising one or more tangs extending radially outward from theouter flowpath ring to engage the casing and thereby space the outerflowpath ring radially inward from the casing forming an annulus betweenthe casing and the outer flowpath ring, and wherein each of theplurality of vanes comprises a member extending into the respectiveannulus; providing a pathway between an entry pathway and an exitpathway, the entry pathway disposed in a first of the compressor stagesand providing an air flowpath between the bulk flowpath of thecompressor stage and the annulus of the stage and the exit pathwaydisposed in a second of the stages positioned axially downstream of thefirst stage, the exit pathway providing an air flowpath between theannulus of the stage and the exterior of the casing, wherein the entrypathway and the exit pathway are in fluid communication; and introducingair flow through the pathway.

In some embodiments the step of introducing air flow through the pathwaycomprises operating the compressor to establish a differential pressurebetween the air pressure proximate the entry pathway and the airpressure proximate the exit pathway. In some embodiments the methodfurther comprises the step of actuating a plurality of vanes of a statorsegment most proximate the entry pathway to alter the vane anglerelative to the direction of bulk flow.

According to yet another aspect of the present disclosure, an axialcompressor comprises a plurality of compressor stages and a casingconfigured to encase the plurality of compressor stages positionedaxially adjacent within the casing. Each of the plurality of compressorstages comprise a rotor segment comprising a bladed disc configured tobe coupled to a rotatable shaft; a banded stator segment positionedaxially adjacent the rotor segment, the stator segment comprising anouter flowpath ring, an inner flowpath ring, and a plurality of vanesextending between the rings and being spaced around the circumferencesthereof, the stator segment further comprising one or more tangsextending radially outward from the outer flowpath ring to engage thecasing and thereby space the outer flowpath ring radially inward fromthe casing forming an annulus between the casing and the outer flowpathring; and a pathway providing an air flowpath between an entry pathwayand an exit pathway, the entry pathway disposed in a first of the stagesand providing an air flowpath between the bulk flowpath of thecompressor stage and the annulus of the stage and the exit pathwaydisposed in a second of the stages positioned axially upstream of thefirst stage, the exit pathway providing an air flowpath between theannulus of the stage and the bulk flowpath of the compressor stage,wherein the entry pathway and the exit pathway are in fluidcommunication.

In some embodiments a pathway in at least one of the stages comprises anaperture formed in the one or more tangs. In some embodiments the firststage is the final downstream stage of the compressor. In someembodiments the second stage is one of the first or second axiallyupstream stages of the compressor. In some embodiments the statorsegment most proximate the entry pathway comprises a plurality ofactuating stator vanes. In some embodiments the entry pathway isdisposed axially forward of a final rotor segment of the compressor. Insome embodiments the entry pathway is disposed axially aft of a finalrotor segment of the compressor.

In some embodiments the entry pathway is disposed at a discharge of thecompressor. In some embodiments the entry pathway comprises a firstaperture disposed axially forward of a final rotor segment of thecompressor and a second aperture disposed axially aft of a final rotorsegment of the compressor. In some embodiments air flow through thepathway is induced by a differential pressure between the air pressureproximate the entry pathway and the air pressure proximate the exitpathway, and wherein the differential pressure is caused by operation ofthe axial compressor.

In some embodiments the exit pathway comprises a plurality of nozzlesdefined by and passing through the outer flowpath ring. In someembodiments the exit pathway comprises a plurality of nozzles defined byand passing through one or more of the plurality of vanes. In someembodiments the plurality of nozzles are disposed proximate a trailingedge of a respective one of the vanes.

According to still another aspect of the present disclosure, an axialcompressor comprises a plurality of compressor stages; a casingconfigured to encase the plurality of compressor stages positionedaxially adjacent within the casing, wherein each of the plurality ofcompressor stages comprise a rotor segment comprising a bladed discconfigured to be coupled to a rotatable shaft; a banded stator segmentpositioned axially adjacent the rotor segment, the stator segmentcomprising an outer flowpath ring, an inner flowpath ring, and aplurality of vanes extending between the rings and being spaced aroundthe circumferences thereof, the stator segment further comprising one ormore tangs extending radially outward from the outer flowpath ring toengage the casing and thereby space the outer flowpath ring radiallyinward from the casing forming an annulus between the casing and theouter flowpath ring; and a pathway providing an air flowpath between anentry pathway and an exit pathway, the pathway comprising a tubeextending from the entry pathway to the exit pathway, wherein the entrypathway is disposed in a first of the stages and provides an airflowpath between the bulk flowpath of the compressor stage and theannulus of the stage, and the exit pathway is disposed in a second ofthe stages positioned axially upstream of the first stage, the exitpathway providing an air flowpath between the annulus of the stage andthe bulk flowpath of the compressor stage, wherein the entry pathway andthe exit pathway are in fluid communication.

In some embodiments the entry pathway is disposed axially forward of afinal rotor segment of the compressor. In some embodiments the entrypathway is disposed axially aft of a final rotor segment of thecompressor. In some embodiments the entry pathway comprises a firstaperture disposed axially forward of a final rotor segment of thecompressor and a second aperture disposed axially aft of a final rotorsegment of the compressor.

In some embodiments the exit pathway comprises a plurality of nozzlesdefined by and passing through the outer flowpath ring. In someembodiments the exit pathway comprises a plurality of nozzles defined byand passing through one or more of the plurality of vanes, and whereinthe plurality of nozzles are disposed proximate a trailing edge of arespective one of the vanes.

According to a further aspect of the present disclosure, a method isprovided of improving the efficiency of an axial compressor. The methodcomprises providing a plurality of compressor stages encased in acasing, the plurality of compressor stages positioned axially adjacentwithin the casing and each of the plurality of compressor stagescomprising: a rotor segment comprising a bladed disc configured to becoupled to a rotatable shaft; a banded stator segment positioned axiallyadjacent the rotor segment, the stator segment comprising an outerflowpath ring, an inner flowpath ring, and a plurality of vanesextending between the rings and being spaced around the circumferencesthereof, the stator segment further comprising one or more tangsextending radially outward from the outer flowpath ring to engage thecasing and thereby space the outer flowpath ring radially inward fromthe casing forming an annulus between the casing and the outer flowpathring; providing a pathway between an entry pathway and an exit pathway,the entry pathway disposed in a first of the stages and providing an airflowpath between the bulk flowpath of the compressor stage and theannulus of the stage and the exit pathway disposed in a second of thestages positioned axially upstream of the first stage, the exit pathwayproviding an air flowpath between the annulus of the stage and the bulkflowpath of the compressor stage, wherein the entry pathway and the exitpathway are in fluid communication; and introducing air flow through thepathway.

In some embodiments the step of introducing air flow through the pathwaycomprises operating the compressor to establish a differential pressurebetween the air pressure proximate the entry pathway and the airpressure proximate the exit pathway. In some embodiments the exitpathway comprises a plurality of nozzles defined by and passing throughthe outer flowpath ring. In some embodiments the exit pathway comprisesa plurality of nozzles defined by and passing through one or more of theplurality of vanes, and wherein the plurality of nozzles are disposedproximate a trailing edge of a respective one of the vanes.

BRIEF DESCRIPTION OF THE DRAWINGS

The following will be apparent from elements of the figures, which areprovided for illustrative purposes and are not necessarily to scale.

FIG. 1A is a side cutaway view of a partially-assembled axial compressorin accordance with some embodiments of the present disclosure.

FIG. 1B is a side cutaway view of a partially-assembled axial compressorin accordance with some embodiments of the present disclosure.

FIG. 1C is a side cutaway view of an axial compressor in accordance withsome embodiments of the present disclosure.

FIG. 2 is a side cutaway view of an axial compressor in accordance withsome embodiments of the present disclosure.

FIG. 3 is an axial profile view of an axial compressor in accordancewith some embodiments of the present disclosure.

FIG. 4A is a side cutaway view of an axial compressor with a coolingpathway in accordance with some embodiments of the present disclosure.

FIG. 4B is a side cutaway view of an axial compressor with a coolingpathway in accordance with some embodiments of the present disclosure.

FIG. 5A is a side cutaway view of an axial compressor with an airinjection pathway in accordance with some embodiments of the presentdisclosure.

FIG. 5B is a side cutaway view of an axial compressor with an airinjection pathway in accordance with some embodiments of the presentdisclosure.

FIG. 6 is a side cutaway view of an axial compressor with one or morecooling pathways through a material having high thermal conductivity inaccordance with some embodiments of the present disclosure.

FIG. 7 is a side cutaway view of an overhung banded stator vane inaccordance with some embodiments of the present disclosure.

FIG. 8A is a side cutaway view of an axial compressor configured forintercooling in accordance with some embodiments of the presentdisclosure.

FIG. 8B is a side cutaway view of an axial compressor configured forintercooling in accordance with some embodiments of the presentdisclosure.

FIG. 9 is a detailed side cutaway view of a stator segment in an axialcompressor in accordance with some embodiments of the presentdisclosure.

FIG. 10 is a detailed side cutaway view of a stator segment in an axialcompressor in accordance with some embodiments of the presentdisclosure.

While the present disclosure is susceptible to various modifications andalternative forms, specific embodiments have been shown by way ofexample in the drawings and will be described in detail herein. Itshould be understood, however, that the present disclosure is notintended to be limited to the particular forms disclosed. Rather, thepresent disclosure is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the disclosure asdefined by the appended claims.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of thedisclosure, reference will now be made to a number of illustrativeembodiments illustrated in the drawings and specific language will beused to describe the same.

This disclosure presents systems and methods of manufacturing andassembling an axial-flow compressor to achieve a less expensivecompressor than is currently available in the art. More specifically,the present disclosure is directed to an axial-flow compressor whichcomprises a tubular casing which encases a rotatable shaft, a pair ofrotor segments coupled to the rotatable shaft and each comprising abladed disc, and a banded stator segment disposed between the pair ofrotor segments and comprising a plurality of stator vanes extendingbetween an outer flowpath ring and an inner flowpath ring. A method ofassembling an axial compressor is further presented, the methodcomprising installing a rotor segment inside a tubular compressorcasing, installing a vane segment adjacent the installed rotor segment,and repeating the steps of installing a rotor segment and vane segmentuntil a desired number of rotor segment and vane segment pairs areinstalled.

FIGS. 1A through 1C present illustrations of the assembly process forthe disclosed an axial compressor 100. FIGS. 1A and 1B show views of apartially assembled axial compressor 100, while a fully assembled axialcompressor 100 is shown in FIG. 1C.

An axial compressor 100 comprises a rotatable assembly 110 and a staticassembly 130. The rotatable assembly 110 may be coupled to a shaft andadapted to rotate about an axis of rotation. The rotatable assembly 110comprises a plurality of rotor segments 120. The static assembly 130comprises a casing 131 which encases the rotatable assembly 110 and aplurality of stator segments 140 disposed in the casing 131.

A fluid flow path is defined through the axial compressor 100 betweenthe casing 131 and a radially inner flow boundary 134 formed by therotor segments 120 and stator segments 140. As fluid passes from anaxially forward end of the compressor 100 to an axially aft end, itpasses between blades 121 of the rotor segments 120 and stator vanes 141of the stator segments 140.

Casing 131 may be a tubular casing or a cylindrical casing, and in someembodiments may be tapered from one axial end to the other axial end.Casing 131 may comprise a first end 132 and second end 133, with thefirst end 132 being axially forward of the second end 133. In someembodiments casing 131 is conical. A conical casing 131 may have asmaller radius at second end 133 than at first end 132. In someembodiments casing 131 may be formed by a rolled ring forging or arolled and welded plate stock. In some embodiments casing 131 may beformed by casting or by a composite and resin method such as a woundcomposite fiber coated with resin and cured.

Casing 131 may be configured to contain axial fluid flow from first end132 to second end 133. In other embodiments casing 131 may be configuredto contain axial fluid flow from second end 133 to first end 132. Casing131 may be adapted to encase a plurality of rotor segments 120, aplurality of stator segments 140, and a shaft 150. Casing 131 may bejoined by forward and aft flanges 135, 136 to additional machinecomponents.

A plurality of rotor segments 120 are disposed inside casing 131. Insome embodiments each rotor segment 120 comprises a bladed disc having aplurality of blades 121 coupled to a disc portion 123. Disc portion 123may be adapted for coupling to shaft 150. In some embodiments each rotorsegment 120 comprises a blade 121 coupled to an annular ring 122 havinga disc portion 123 for connecting the rotor segment 120 to the shaft150. Each rotor segment 120 may be referred to as a stage of thecompressor.

In some embodiments rotor segment includes an axially-extending sealingarm 124. Sealing arm 124 may be formed integrally with the annular ring122 or may be formed separately and coupled to annular ring 122. In someembodiments sealing arm 124 may have a plurality of annular knife edges125 extending radially outward and adapted to engage a portion of astator segment 140 in order to effectively form a seal. The seal may bereferred to as a knife edge seal. In some embodiments the seal formed isa labyrinth seal.

During operation, rotor segments 120, including any sealing anus 124,rotate with shaft 150. The motion of blades 121 drives fluid from theaxially forward first end 132 to the axially aft second end 133.

A plurality of stator segments 140 are disposed inside casing 131. Eachstator segment 140 comprises an outer flowpath ring 141, an innerflowpath ring 143, and a plurality of stator vanes 142 extending betweenthe outer flowpath ring 141 and inner flowpath ring 143. Stator vanes142 may be spaced about the circumference of outer flowpath ring 141 andinner flowpath ring 143. Stator segments 140 may be referred to as abanded stator segment, as the stator vane 142 and fluid flow may bebanded between outer flowpath ring 141 and inner flowpath ring 143. Eachstator segment 140 may be referred to as a stage of the compressor.

In some embodiments, stator vanes 142 are hot upset to one or both ofouter flowpath ring 141 and inner flowpath ring 143. During hot upsetprocessing, one or more tangs extending from the end of a stator vane142 is inserted into one or more slots, respectively, of a flowpathring. The tang is heated and then deformed to couple the stator vane 142to the flowpath ring.

Outer flowpath ring 141 is annular and may extend axially forward or aftsuch that outer flowpath ring 141 is disposed radially outward from oneor more adjacent rotor segments 120. Outer flowpath ring 141 may beadapted to couple with casing 131, for example through a tongue andgroove, a keyway, or the use of tangs as described in greater detailbelow. In some embodiments outer flowpath ring 141 includes an abradablering 146 adapted to ensure that the tip of a blade 121 does not impingethe casing 131 or the outer flowpath ring 141. Abradable ring 146 may beformed from a material which is softer or more maleable than thematerials which form the casing 131 or the outer flowpath ring 141.Abradable ring 146 is radially disposed between the blade tips 127 ofone of the rotor segments 120 and the casing 131.

Inner flowpath ring 143 is annular and may include a radially inwardfacing sealing member 145 which is adapted to engage a portion of asealing arm 124 of a rotor segment 120. In some embodiments sealingmember 145 engages a plurality of knife edges 125 extending from sealingarm 124 to form a labyrinth seal. In some embodiments sealing member 145may be formed as an annular ring. In other embodiments, sealing member145 comprises a coating applied to inner flowpath ring 143.

During operation, stator segments 140 remain fixed or stationary.

Rotor segments 120 and stator segments 140 are disposed inside casing131 in alternating fashion, such that stator segments 140 are disposedbetween a pair of rotor segments 120. In some embodiments, such as thatshown in FIG. 1C, axial compressor 100 comprises five rotor segments 120and four stator segments 140. In other embodiments rotor segments 120and stator segments 140 are disposed in pairs and thus an equal numberof rotor segments 120 and stator segments 140 are disposed inside casing131. Each rotor segment 120 and stator segment 140 pair may be referredto as a stage of the compressor.

A radially inner flow boundary 134 is formed by the annular surface 126of ring 122 of rotor segment 120 and the annular surface 144 of innerflowpath ring 143 of stator segment 140. The flow boundary 134 may beinterrupted by various cavities adjacent the seals between the rotorsegments 120 and stator segments 140.

In some embodiments a fluid diffuser 155 is disposed in second end 133and further defines the fluid flowpath in the axially aft direction.Diffuser 155 may comprise a sealing member 157 adapted to engage atleast a portion of a sealing arm 124 of a rotor segment 120. In someembodiments sealing member 157 engages a plurality of knife edges 125extending from sealing arm 124 to form a labyrinth seal. In someembodiments sealing member 157 may be formed as an annular ring. Inother embodiments, sealing member 157 comprises a coating applied todiffuser 155. Diffuser 155 may further comprises a plurality of guidevanes.

In some embodiments the plurality of rotor segments 120 and statorsegments 140 may be held in compression by a compressive element, forexample a threaded bolt between first end 132 and second end 133 ofcasing 131.

In some embodiments spacers (not shown) may be included between one ormore of the plurality of rotor segments 120 and stator segments 140.

In some embodiments one or more of the plurality of blades 121 andstator vanes 142 are fabricated using stamping, injection moldingincluding metal injection molding, and/or composite and resinfabrication. In some embodiments blades 121 are coupled to annular ring122 using brazing, welding, or adhesive. In some embodiments statorvanes 142 are coupled between outer flowpath ring 141 and inner flowpathring 143 using brazing, welding, or adhesive.

With reference now to FIG. 1A, the assembly of the disclosed axialcompressor will be described. FIG. 1A is a side cutaway view of apartially-assembled axial compressor 100. As shown in FIG. 1A, adiffuser segment 155 is initially installed at second end 133 of casing131. Diffuser segment 155 may act as a backstop which prevents axiallyaft movement of rotor segments 120 and stator segments 140. In someembodiments diffuser segment 155 comprises an abradable ring 159 whichextends axially forward and is disposed radially outward from a rotorassembly 120.

A rotor assembly 120 is inserted into casing 131 at first end 132 andmoved axially aft toward second end 133. When in position, a sealing arm124 may extend from rotor assembly 120 and engage a sealing member 157of diffuser segment 155.

Following the insertion and position of rotor assembly 120, as shown inFIG. 1A a stator segment 140 is inserted into casing 131 at first end132 and moved axially aft toward second end 133. FIG. 1B is a sidecutaway view of a partially-assembled axial compressor 100 and shows thestator segment 140 which was inserted in FIG. 1A in a final position. Insome embodiments stator segment 140 may be positioned adjacent theaxially-forward side of rotor segment 120. In some embodiments statorsegment 140 may be positioned abutting the axially-forward side of rotorsegment 120. As shown in FIG. 1B, stator segment 140 comprises anabradable ring 146 which extends axially forward to be disposed betweena subsequently-inserted rotor portion 120 and casing 131. In someembodiments stator segment 140 may include an abradable ring 146 whichextends axially aft to be disposed between the previously-inserted rotorportion 120 and casing 131.

Once the stator segment 140 is positioned as shown in FIG. 1B,additional rotor segments 120 and stator segments 140 are inserted intocasing 131 at first end 132 and moved axially aft toward second end 133.Rotor segments 120 and stator segments 140 are positioned in alternatingfashion.

FIG. 1C is a side cutaway view of an axial compressor 100 following theassembly process as described above with reference to FIGS. 1A and 1B.

FIG. 2 is a side cutaway view of an axial compressor 200 in accordancewith some embodiments of the present disclosure. Axial compressor 200comprises a plurality of rotor segments 120 and stator segments 240disposed inside a compressor casing 131. Rotor segments 120 are coupledto rotatable shaft 150.

Stator segments 240 comprise an outer flowpath ring 141, an innerflowpath ring 143, and a plurality of stator vanes 142 extending betweenthe outer flowpath ring 141 and inner flowpath ring 143. Stator vanes142 may be spaced about the circumference of outer flowpath ring 141 andinner flowpath ring 143.

Stator segments 240 further comprise a pair of opposing tangs 261, 262extending radially outward from the outer flowpath ring 141 in order tospace the outer flowpath ring 141 radially inward from the casing 131.Tangs 261 and 262 have curved ends which are configured to engage casing131 and assist in maintaining the position, once assembled, of statorsegments 240. In some embodiments adjacent stator segments 240 may becoupled using one or more fasteners 271, 272. In some embodimentsfasteners 271 and 272 may be used to fasten adjacent or abutting tangs261, 262. In some embodiments fasteners 271 and 272 comprise pins whichprevent rotation of stator segments 140 during operation.

Outer flowpath ring 141 is annular and may extend axially forward or aftsuch that outer flowpath ring 141 is disposed radially outward from oneor more adjacent rotor segments 120. In some embodiments outer flowpathring 141 includes an abradable ring 146 adapted to ensure that the tipof a blade 121 does not impinge the casing 131 or the outer flowpathring 141. Abradable ring 146 may be formed from a material which issofter or more maleable than the materials which form the casing 131 orthe outer flowpath ring 141. Abradable ring 146 is radially disposedbetween the blade tips 127 of one of the rotor segments 120 and thecasing 131.

An outer flow boundary 280 is formed by the radially inner surfaces ofeach stator segment 240.

FIG. 3 is an axial profile view of an axial compressor 100 viewed froman axially forward position and looking in an axially aft direction. Theaxial cross-section shown in FIG. 3 is taken at a stator segment 140.Compressor 100 is defined in the radially outward direction by casing131. A fluid flowpath 300 is partially bounded in a radially outwarddimension by the radially inner surface of outer flowpath ring 141 andis partially bounded in a radially inward dimension by the radiallyouter surface of inner flowpath ring 143. A plurality of stator vanesare disposed circumferentially about and between the outer flowpath ring141 and inner flowpath ring 143.

The disclosed axial compressor as described above has numerous andvaried applications in the field of fluid compression. Such applicationsinclude, but are not limited to, aviation applications such as gasturbine engines for aircraft and unmanned aerial vehicles (UAVs),expendable compressor applications such as for missile propulsionsystems, land- and sea-based gas turbine engines providing electricalgeneration and/or propulsion, and any rotating machinery generally.

The present disclosure provides many advantages over previous axialcompressors. In particular, significant cost savings may be achieved bysimplicity of design; reduction or elimination of numerous fasteners,discs, and seal assemblies currently required in advanced compressordesigns; ease of manufacture and assembly; and substitution of lessexpensive composite materials for metal and metal-based materials.

According to further aspects of the present disclosure, systems andmethods are provided of cooling the axial compressor 200 describedabove. FIGS. 4A and 4B are side cutaway views of an axial compressor 200with a cooling pathway 401 in accordance with some embodiments of thepresent disclosure.

As discussed above, axial compressor 200 comprises a plurality of statorsegments 240 and rotor segments 120 which are positioned axiallyadjacent to each other in alternating fashion within a casing 131. Eachstator segment 240 comprises an inner flowpath ring 143, an outerflowpath ring 141, and a plurality of stator vanes 142. The vanes 142extend between and are positioned about the circumference of the innerflowpath ring 143 and outer flowpath ring 141. In some embodiments oneor more stator segments 240 has vanes 142 that are variable pitch vanescapable of actuating to adjust their angle relative to the direction ofbulk flow.

A pair of tangs 261, 262 extend from and engage the outer flowpath ring141 to the casing 131. Together the outer flowpath ring 141, tangs 261,262, and casing 131 form an annulus 403 of each stator segment 240.Tangs 261, 262 therefore space the outer flowpath ring 141 from thecasing 131 and form the annulus 403 between the outer flowpath ring 141and casing 131.

Each rotor segment comprises a bladed disc 120 configured to be coupledto a rotating shaft 150.

An outer flow boundary 280 is formed by the radially inner surfaces ofeach stator segment 240. An inner flow boundary 281 is formed by innerflow ring 143 of rotor segment 120 and sealing arms 124 extendingbetween rotor segments 120 and stator segments 240. A main or bulkflowpath 405 of the compressor 200 is defined between the outer flowboundary 280 and the inner flow boundary 281 of the compressor. Air flowin the bulk flowpath 405 is indicated with the arrow labeled “Bulk.”

A pathway 401 is provided at least between the annuli 403 of any twoadjacent stator segments 240. Air flow through pathway 401 isillustrated as arrow A1. In some embodiments, such as that illustratedin FIG. 4A, a pathway 401 is provided between the bulk flowpath 405 andambient air 407 located radially outward of the casing 131. Pathway 401may be defined as one or more apertures 409 in the tangs 261, 262 ofadjacent stator segments 240. In the embodiment shown in FIG. 4A, anentry pathway comprises an aperture 411 permitting air flow between thebulk flowpath 405 and an annulus 403 of a stator segment 240. Additionalapertures 409 permit air flow to adjacent annuli 403. An exit pathwaycomprises an aperture 413 permitting air flow between an annulus 403 ofa stator segment 240 and ambient air 407. Exit pathway 413 is positionedaxially downstream of the entry pathway 411.

In operation, air pressure proximate the entry pathway 411 is greaterthan air pressure proximate the exit pathway 413 because air proximatethe entry pathway 411 has passed through at least a first stage of thecompressor 200. Air flow is thus induced from the relatively higherpressure proximate the entry pathway 411 to the relatively lowerpressure of ambient air 407 proximate the exit pathway 413. The inducedair flow through pathway 401 provides cooling of each annulus 403 of astator segment 240, and thus provides cooling to later stages of thecompressor 200 as heat generated in later stages is transferred from thebulk flowpath 405 to the annulus 403 and then out to ambient via coolingair flow.

During manufacture of the axial compressor 200, rotor segments 120 andstator segments 240 are alternately installed in the casing 131. Rotorsegments 120 are secured to the rotatable shaft 150, and stator segments240 are secured inside the casing 131 via tangs 261, 262 which areconfigured to friction fit into the casing. In some embodimentsadditional fasteners or adhesive may be applied to the tang-casinginterface. Each rotor segment 120-stator segment 240 pair comprises astage of the compressor 200.

In some embodiments a plurality of apertures 409 are provided in eachtang 261, 262 and spaced circumferentially and/or radially about thetang 261, 262. It is therefore important during assembly of thecompressor 200 to ensure that apertures 409 of a first stator segment240 are aligned with apertures 409 of axially adjacent stator segments240 to ensure the formation of a pathway 401.

A method of cooling axial compressor 200 comprises providing an axialcompressor 200 as substantially described above, specifically as havingstator segments 240 defining an annulus 403 such that the outer flowpathring 141 is radially inwardly spaced from casing 131. The providedcompressor 200 further comprises a pathway 401 between adjacent annuli403, and in some embodiments comprises a pathway 401 from the bulkflowpath 405 to ambient air 407 via at least two annuli 403. The methodfurther comprises introducing air flow, typically through operation ofthe compressor 200 which creates a differential pressure across thepathway 401, such that relatively cooler air flows through the pathway401 and removes heat from later stages of the compressor 200.

In another embodiment, shown in FIG. 4B, pathway 401 is defined by atube 415 passing from the entry pathway 411 to the exit pathway 413.Tube 415 may be advantageously provided to reduce or eliminate turbulentflow through each annulus 403 of a stator segment 240. The flow ofrelatively cooler air through a tube 415 proximate the casing 131 mayalso create a thermal gradient across the annulus 403, with relativelywarmer air proximate the outer flow ring 141. The use of tube 415additionally allows for multiple discrete flowpaths through the annulus403, for example by allowing both cooling airflow and air injectionairflow or by allowing multiple cooling flowpaths.

FIG. 6 presents a side cutaway view of an axial compressor 200 with oneor more cooling pathways through a material having high thermalconductivity in accordance with some embodiments of the presentdisclosure. In the embodiment illustrated in FIG. 6, one or more annuli403 of the compressor 200 are substantially filled with a filler 602that defines one or more pathways 604A, 604B.

In some embodiments filler 602 is formed from a high thermallyconductive material 602. For example, filler 602 may be formed from ametallic foam material such as an aluminum-, copper-, silver-, orgraphite-based foam. For example, in some embodiments filler 602 may bemade from POCOFoam®. In other embodiments other materials having a highthermal conductivity will be utilized to make filler 602. In someembodiments a material having a high radial thermal conductivity but alow axial thermal conductivity will be utilized as filler 602.

One or more pathways 604A, 604B are provided at least between the annuli403 of any two adjacent stator segments 240. Air flow entering pathways604A, 604B is illustrated as arrow A3, while air flow exiting pathways604A, 604B is illustrated as arrow A4. In some embodiments such as thatillustrated in FIG. 6, pathways 604A, 604B are provided between the bulkflowpath 405 and ambient air 407 located radially outward of the casing131. Pathways 604A, 604B may be defined by filler 602 as well as one ormore apertures 409 in the tangs 261, 262 of adjacent stator segments240. In the embodiment shown in FIG. 6, an entry pathway comprises anaperture 411 permitting air flow between the bulk flowpath 405 and theone or more pathways 604A, 604B defined by filler 602 of an annulus 403of a stator segment 240. Additional apertures 409 permit air flow toadjacent annuli 403. An exit pathway comprises an aperture 413permitting air flow between an annulus 403 of a stator segment 240 andambient air 407. Exit pathway 413 is positioned axially downstream ofthe entry pathway 411.

In operation, air pressure proximate the entry pathway 411 is greaterthan air pressure proximate the exit pathway 413 because air proximatethe entry pathway 411 has passed through at least a first stage of thecompressor 200. Air flow is thus induced from the relatively higherpressure proximate the entry pathway 411 to the relatively lowerpressure of ambient air 407 proximate the exit pathway 413. The inducedair flow through pathways 604A, 604B provides cooling of each annulus403 of a stator segment 240, and thus provides cooling to later stagesof the compressor 200 as heat generated in later stages is transferredfrom the bulk flowpath 405 to the annulus 403 and then out to ambientair 407 via cooling air flow. Filler 602, having a high thermalconductivity, improves the efficiency of this heat transfer from thebulk flowpath 405 to the annulus 403 and on to the ambient air 407.

In some embodiments a plurality of apertures 409 are provided in eachtang 261, 262 and spaced circumferentially and/or radially about thetang 261, 262. For example, in the embodiment illustrated in FIG. 6several stator segments 240 have a first pathway 604A and a secondpathway 604B which are radially spaced from each other. It is thereforeimportant during assembly of the compressor 200 to ensure that theapertures 409 and pathways 604A, 604B defined by filler 602 of a firststator segment 240 are aligned with apertures 409 and pathways 604A,604B of axially adjacent stator segments 240 to ensure the formation ofpathways 604A, 604B that are in fluid communication from one statorsegment 240 to the next.

A method of cooling axial compressor 200 comprises providing an axialcompressor 200 as substantially described above with reference to FIG.6, specifically as having stator segments 240 defining an annulus 403such that the outer flowpath ring 141 is radially inwardly spaced fromcasing 131. One or more annuli 403 of the compressor 200 aresubstantially filled with a filler 602 having a high thermalconductivity. The provided compressor 200 further comprises one or morepathways 604A, 604B between adjacent annuli 403, and in some embodimentscomprises one or more pathways 604A, 604B from the bulk flowpath 405 toambient air 407 via at least two annuli 403. The method furthercomprises introducing air flow, typically through operation of thecompressor 200 which creates a differential pressure across the pathways604A, 604B, such that relatively cooler air flows through the pathways604A, 604B and removes heat from later stages of the compressor 200.

The embodiments of FIGS. 4A, 4B, and 6 advantageously remove heat fromcompressor 200, which allow for the use of certain materials such ascomposite materials in the manufacture of the compressor 200.

The present disclosure additional provides systems and methods ofintercooling an axial compressor. Intercooling improves the efficiencyof a compressor by extracting heat between compressor stages. Removingheat reduces the volume of fluid to be compressed, thus saving work.FIGS. 8A and 8B present a side cutaway views of an axial compressorconfigured for intercooling in accordance with some embodiments of thepresent disclosure.

In the embodiments of FIGS. 8A and 8B, portions of one or more statorvanes 142 extend through and radially outward beyond the respectiveouter flowpath ring 141. These portions are labeled as extending members631. Each extending member 631 passes through a corresponding aperture(not shown) of the outer flowpath ring 141 and into the annulus 403.Each annulus 403 may be substantially open as illustrated in FIG. 8A anddescribed above, for example, with reference to FIG. 4A, or may besubstantially filled as illustrated in FIG. 8B and described above, forexample, with reference to FIG. 6. In embodiments having a substantiallyfilled annulus 403, one or more extending members 631 may extend intofiller 602.

Extending members 631 provide compressor intercooling by assisting withthe radially outward transfer of heat at each stage of the compressor.As stator vanes 142 heat up during operation of the compressor 200, heatis transferred radially outward from vane 142 to extending member 631.Extending member 631 extends into the annulus 403, filler 602, and/orpathways 604A, 604B. The introduction of cooling air flow through theannuli 403 and/or pathways 604A, 604B results in the flow of cooling airacross or around one or more of the extending members 631. Heattransferred to the cooling air flow is then transferred to ambient air407.

The present disclosure further provides systems and methods forimproving the efficiency of compressor 200 described above through theinjection of relatively higher pressure air into earlier stages of thecompressor 200, which may be referred to as air injection. Injection ofhigh pressure air at early stages of the compressor 200 increases theenergy of air flowing through the bulk flowpath 408 and causesdisruptions in any boundary layer that may form proximate the outer flowboundary 280 and/or the inner flow boundary 281 of the compressor 200.Reduction or elimination of a boundary layer improves compressorefficiency. FIGS. 5A and 5B are side cutaway views of an axialcompressor 200 with an air injection pathway 501 in accordance with someembodiments of the present disclosure. FIGS. 9 and 10 are detailed sidecutaway views of a stator segment in an axial compressor in accordancewith some embodiments of the present disclosure.

Pathway 501 is provided at least between the annuli 403 of any twoadjacent stator segments 240. Air flow through pathway 501 isillustrated as arrow A2. In some embodiments, such as that illustratedin FIG. 5A, a pathway 501 is provided between the bulk flowpath 405 at apoint proximate the compressor discharge 520 and the bulk flowpath 405at a point proximate the compressor inlet 522. In other words, pathway501 provides an air flowpath from relatively later stages to relativelyearlier stages of the compressor 200.

Pathway 501 may be defined as one or more apertures 509 in the tangs261, 262 of adjacent stator segments 240. In the embodiment shown inFIG. 5A, one or more entry pathways 511A, 511B are provided, with eachentry pathway 511A, 511B comprising an aperture 511 permitting air flowbetween the bulk flowpath 405 proximate the compressor discharge 520 andan annulus 403 of a stator segment 240. In some embodiments only one ofentry pathways 511A and 511B are provided in the compressor 200. Inother embodiments, both entry pathways 511A and 511B are provided in thecompressor 200.

Additional apertures 509 permit air flow to adjacent annuli 403. An exitpathway comprises an aperture 513 permitting air flow between an annulus403 of a stator segment 240 and the bulk flowpath 405 proximate thecompressor inlet 522. Exit pathway 513 is positioned axially upstream ofthe one or more entry pathways 511A, 511B.

In some embodiments exit pathway 513 comprises a plurality of nozzles902 defined by and passing through the outer flowpath ring 141. FIG. 9is a depiction of such an embodiment. Air flow A2 passes throughaperture 409 to cross from one annulus 403 to an adjacent annulus 403.Air flow A2 then passes through one or more nozzles 902 to cross fromannulus 403 to the bulk flowpath 405. Upon entering the bulk flowpath405, the high energy air flow A2 disrupts the formation or continuationof an boundary layer proximate the outer flow boundary 280 and/or theinner flow boundary 281 of the compressor 200. Based on the location ofnozzles 902 in the outer flowpath ring 141, the embodiment of FIG. 9would likely be more effective at preventing or reducing the boundarylayer proximate the outer flow boundary 280.

In some embodiments exit pathway 513 comprises a plurality of nozzles orapertures 1002 defined by and passing through stator vane 142. FIG. 10is a depiction of such an embodiment. A pathway 1004 is defined interiorto the stator vane 142. Pathway 1004 is in fluid communication with arespective annulus 403 via an aperture 1006. Nozzles 1002 may bepositioned proximate the trailing edge 1008 of stator vane 142. In theillustrated embodiment, nozzles 1002 are configured as a single row ofnozzles 1002 oriented substantially parallel to trailing edge 1008.However, additional nozzle configurations are contemplated, such asmultiple rows, nozzle groupings, and alternative placements along thestator vane 142.

Air flow A2 passes through aperture 409 to cross from one annulus 403 toan adjacent annulus 403. Air flow A2 then passes through aperture 1006and into pathway 1004. From there, air flow A2 passes through one ormore nozzles 1002 to cross from annulus 403 to the bulk flowpath 405.Upon entering the bulk flowpath 405, the high energy air flow A2disrupts the formation or continuation of an boundary layer proximatethe outer flow boundary 280 and/or the inner flow boundary 281 of thecompressor 200.

In operation, air pressure proximate the entry pathways 511A, 511B isgreater than air pressure proximate the exit pathway 513 because airproximate the entry pathways 511A, 511B has passed through most stagesof the compressor 200, while air flow proximate the exit pathway 513 haspassed through relatively fewer stages of the compressor 200. Air flowis thus induced from the relatively higher pressure proximate the entrypathways 511A, 511B to the relatively lower pressure proximate the exitpathway 513. The induced air flow through pathway 501 increases the airpressure in earlier stages of the compressor 200, and thus improves theefficiency of the compressor through disruption, reduction, and/orprevention of a boundary layer proximate the outer flow boundary 280and/or the inner flow boundary 281.

In some embodiments a plurality of apertures 509 are provided in eachtang 261, 262 and spaced circumferentially and/or radially about thetang 261, 262. It is therefore important during assembly of thecompressor 200 to ensure that apertures 509 of a first stator segment240 are aligned with apertures 509 of axially adjacent stator segments240 to ensure the formation of a pathway 501.

A method of improving the efficiency of axial compressor 200 comprisesproviding an axial compressor 200 as substantially described above,specifically as having stator segments 240 defining an annulus 403 suchthat the outer flowpath ring 141 is radially inwardly spaced from casing131. The provided compressor 200 further comprises a pathway 501 betweenadjacent annuli 403, and in some embodiments comprises a pathway 501from the bulk flowpath 405 proximate the compressor discharge 520 to thebulk flowpath 405 proximate the compressor inlet 522 via at least twoannuli 403. The method further comprises introducing air flow, typicallythrough operation of the compressor 200 which creates a differentialpressure across the pathway 501, such that relatively higher pressureair flows through the pathway 501 and increases air pressure in arelatively earlier compressor stage.

In another embodiment, shown in FIG. 5B, pathway 501 is defined by atube 515 passing from the entry pathway 511 to the exit pathway 513.Tube 515 may be advantageously provided to reduce or eliminate turbulentflow through each annulus 403 of a stator segment 240. The use of tube515 additionally allows for multiple discrete flowpaths through theannulus 403, for example by allowing both cooling airflow and airinjection airflow or by allowing multiple cooling flowpaths.

In some embodiments, the pathways 401 and 501 are each provided in thesame compressor 200, allowing cooling airflow to pass through tubes 415in an axially forward-to-aft direction while simultaneously allowing airinjection to pass through tubes 515 in an axially aft-to-forwarddirection. Tubes 415 and 515 are spaced apart about the circumference ofeach stator segment 240.

FIG. 7 is a side cutaway view of a stator vane configuration inaccordance with some embodiments of the present disclosure. In any ofthe above embodiments, the stator vane 142 of a stator segment 240 maybe an overhung banded stator vane 702 such as that illustrated in FIG.7. Vane 702 comprises a bulk flow portion 703 and an extending member631. Bulk flow portion 703 extends between outer flowpath ring 141 andinner flowpath ring 143. Extending member 631 passes through the outerflowpath ring 141 and into the annulus 403.

A tang 262 extends from the outer flowpath ring 141 to casing 131 asdescribed above. At an opposite axial end of the outer flowpath ring 141of the stator segment 240, a rolled outer band 705 extends radiallyoutward from the outer flowpath ring 141 for a first portion 706 andthen axially for a second portion 707. The axially extending secondportion 707 is coupled to extending member 631 of the stator vane 142.In some embodiments, outer flowpath ring 141 and first and secondportions 706, 707 of rolled outer band 705 are formed as a unitarymember. In some embodiments tang 262, outer flowpath ring 141, and firstand second portions 706, 707 of rolled outer band 705 are formed as aunitary member.

The overhung banded stator 702 disclosed in FIG. 7 advantageouslyprovides additional axial, radial, and circumferential support to thestator vane 142 of the stator segment 240.

Although examples are illustrated and described herein, embodiments arenevertheless not limited to the details shown, since variousmodifications and structural changes may be made therein by those ofordinary skill within the scope and range of equivalents of the claims.

What is claimed is:
 1. An axial compressor comprising: a plurality ofcompressor stages; a casing configured to encase said plurality ofcompressor stages positioned axially adjacent within said casing,wherein each of said plurality of compressor stages comprises: a rotorsegment comprising a bladed disc configured to be coupled to a rotatableshaft; a banded stator segment positioned axially adjacent said rotorsegment, said stator segment comprising an outer flowpath ring, an innerflowpath ring, and a plurality of vanes extending between said rings andbeing spaced around the circumferences thereof, said stator segmentfurther comprising one or more tangs extending radially outward fromsaid outer flowpath ring to engage said casing and thereby space saidouter flowpath ring radially inward from said casing forming an annulusbetween said casing and said outer flowpath ring; wherein each of saidplurality of vanes comprises a member extending into the annulus; andwherein each annulus is in fluid communication with each other annulusof the plurality of compressor stages, wherein said fluid communicationis facilitated via at least one pathway, and said pathway in at leastone of said stages comprises an aperture formed in said one or moretangs.
 2. The axial compressor of claim 1, wherein said pathway providesan air flowpath between said annulus and the annulus formed by anadjacent stage.
 3. The axial compressor of claim 2, further comprising:an entry pathway in a first of said stages providing an air flowpathbetween the main flowpath of said compressor stage and the annulus ofsaid stage; and an exit pathway in a second of said stages positionedaxially downstream of said first stage, said exit pathway providing anair flowpath between the annulus of said stage and the exterior of saidcasing.
 4. The axial compressor of claim 3, where said second stage isthe final downstream stage of said compressor.
 5. The axial compressorof claim 3, where said first stage is one of the first or second axiallyupstream stages of the compressor.
 6. The axial compressor of claim 3,wherein the stator segment most proximate said entry pathway comprises aplurality of actuating stator vanes.
 7. The axial compressor of claim 3,wherein said pathway is defined by a tube extending between said entrypathway and said exit pathway.
 8. The axial compressor of claim 3,wherein air flow through said pathway is induced by a differentialpressure between the air pressure proximate the entry pathway and theair pressure proximate the exit pathway, and wherein said differentialpressure is caused by operation of said axial compressor.
 9. The axialcompressor of claim 1, wherein each of said members passes through arespective aperture of said outer flowpath ring.
 10. The axialcompressor of claim 1, wherein said annulus of one or more of saidstator segments is substantially filled with a filler.
 11. The axialcompressor of claim 10, wherein said filler comprises a metallic foam.12. The axial compressor of claim 11, wherein said filler has a higherthermal conductivity in the radial direction than in the axialdirection.
 13. The axial compressor of claim 10, wherein said pathwaycomprises an air flowpath between an entry aperture and an exitaperture, said entry aperture disposed in a first of said compressorstages and providing an air flowpath between the bulk flowpath of saidcompressor stage and the annulus of said stage and said exit aperturedisposed in a second of said stages positioned axially downstream ofsaid first stage, said exit aperture providing an air flowpath betweenthe annulus of said stage and the exterior of said casing, wherein saidentry aperture and said exit aperture are in fluid communication. 14.The axial compressor of claim 13, wherein a plurality of pathways aredefined by said filler between said entry aperture and said exitaperture.
 15. The axial compressor of claim 1, wherein fluidcommunication between each annulus of the plurality of compressor stagescauses fluid flow proximate each member.
 16. An axial compressorcomprising: a plurality of compressor stages; a casing configured toencase said plurality of compressor stages positioned axially adjacentwithin said casing, wherein each of said plurality of compressor stagescomprises: a rotor segment comprising a bladed disc configured to becoupled to a rotatable shaft; a banded stator segment positioned axiallyadjacent said rotor segment, said stator segment comprising an outerflowpath ring, an inner flowpath ring, and a plurality of vanesextending between said rings and being spaced around the circumferencesthereof, said stator segment further comprising one or more tangsextending radially outward from said outer flowpath ring to engage saidcasing and thereby space said outer flowpath ring radially inward fromsaid casing forming an annulus between said casing and said outerflowpath ring and wherein said annulus is substantially filled with afiller that defines one or more pathways between said annulus and theannulus formed by an adjacent stage, said pathway extending through eachannulus of the plurality of compressor stages; and wherein each of saidplurality of vanes comprises a member extending into the annulus.
 17. Amethod of intercooling an axial compressor comprising: providing aplurality of compressor stages encased in a casing, said plurality ofcompressor stages positioned axially adjacent within said casing andeach of said plurality of compressor stages comprising: a rotor segmentcomprising a bladed disc configured to be coupled to a rotatable shaft;a banded stator segment positioned axially adjacent said rotor segment,said stator segment comprising an outer flowpath ring, an inner flowpathring, and a plurality of vanes extending between said rings and beingspaced around the circumferences thereof, said stator segment furthercomprising one or more tangs extending radially outward from said outerflowpath ring to engage said casing and thereby space said outerflowpath ring radially inward from said casing forming an annulusbetween said casing and said outer flowpath ring, wherein each of saidplurality of vanes comprises a member extending into the respectiveannulus, and wherein each annulus is in fluid communication with eachother annulus of the plurality of compressor stages; providing a pathwaybetween an entry pathway and an exit pathway, said entry pathwaydisposed in a first of said compressor stages and providing an airflowpath between the bulk flowpath of said compressor stage and theannulus of said stage and said exit pathway disposed in a second of saidstages positioned axially downstream of said first stage, said exitpathway providing an air flowpath between the annulus of said stage andthe exterior of said casing, wherein said entry pathway and said exitpathway are in fluid communication; and introducing air flow throughsaid pathway.
 18. The method of claim 17, wherein the step ofintroducing air flow through said pathway comprises operating saidcompressor to establish a differential pressure between the air pressureproximate the entry pathway and the air pressure proximate the exitpathway.
 19. The method of claim 17, further comprising the step ofactuating a plurality of vanes of a stator segment most proximate saidentry pathway to alter the vane angle relative to the direction of bulkflow.